12/01/2024 01:25:41

Rear Drive Unit - Mosfet - HC (3DU) (Remove and Replace)

Correction code 4001020102 FRT 3.78 NOTE: Unless otherwise explicitly stated in the procedure, the above correction code and FRT reflect all of the work required to perform this procedure, including the linked procedures. Do not stack correction codes unless explicitly told to do so. NOTE: See Flat Rate Times to learn more about FRTs and how they are created. To provide feedback on FRT values, email LaborTimeFeedback@tesla.com. NOTE: See Personal Protection to make sure wearing proper PPE when performing the below procedure.

2024-01-24: Added a note to install a new motor ID label in hood/trunk for China, Japan and Korea.
2023-12-11: Updated last step with cross reference to Alignment Requirement Tables.

Warning

This procedure is a DRAFT, although it has been validated. Warnings and Cautions might be missing. Follow safety requirements and use extreme caution when working on or near high voltage systems and components. Provide corrections and feedback to ServiceDevelopment@teslamotors.com.

Remove

Inspect the tires for abnormal wear.

Note
Note any abnormal tire wear that could indicate the need for an alignment.
Raise and support vehicle.

Note
Ensure vehicle is not charging.
Open all four doors.

Note
If vehicle is being powered down, Latch rear doors to prevent accidental closure.
Lower all four windows.
Move LH front seat forward.
Move RH front seat forward.
Place vehicle in service mode through UI.

Note
Select vehicle's badge icon in Controls > Software for four seconds and then type "service" into dialog box.
Unlock vehicle gateway.

Note
After vehicle has been put into "Service Mode", place keycard on center console to turn on drive rails, hold down the brake pedal, while keep pressing right hand signal button simultaneously for at least 10 seconds, "GTW UNLOCKING" should pop up on the UI right next to the VIN during these 10 seconds, once gateway is unlocked "GTW UNLOCKED 5400" will be displayed on the UI next to the VIN, the gateway will remain unlocked for 90 minutes, follow steps on Toolbox article #5582900 for any additional information.
Run Thermal Fill Drain (Coolant Only) through the UI.

Note
Select Thermal > Coolant System > Coolant Fill/Drain, click Run, close once routine is completed, Thermal Fill Drain routine has a 5 hour time limit, After 5 hours routine must be performed again.
Place vehicle into tow mode.

Note
Via Controls > Service > ''Towing'' .
Open hood.
Remove rear underhood apron.

Note
14x clips.
Power off vehicle from center display.

Note
Via Controls > Safety > Power Off, Select Power Off button at warning dialogue box.
Disconnect LV battery and First Responder Loop.

Note
2x connectors, Release green locking tab, Press black tab then pull black connector lock outwards to release connection, Release red lock tab on FRL, Allow 2 minutes for all electrical circuits to fully discharge.
Release 2nd row seat cushion and disconnect harness.

Note
2x clips, 2x connectors, Press tabs backward then pull front edge up.
Verify operation of multimeter.

Note
Set multimeter to DC voltage, Confirm multimeter is properly measuring voltage by testing the 16v battery.
Remove all items from pockets and ensure not wearing metal items.
Inspect HV insulating gloves.

Note
Check gloves for damage prior to use, Refer to service document TN-15-92-003 R1, for information on inspecting HV gloves.
Put on HV insulating gloves and leather over gloves.

Note
Make sure to wear Electrical Protective Gloves any time Hioki tester is used.
Remove bolts securing ancillary bay probe lid cover to ancillary bay cover.

Note
2x bolts, EP10 5-Lobe, 6 Nm, Discard after removal.
Remove ancillary bay probe lid cover from ancillary bay cover.
Verify no high voltage.

Note
Make sure to wear PPE (HV gloves, safety glasses) when working on high voltage component, If voltage is greater than 10V, Pack contactors are not open or welded, Stop work and reach out to Service Engineering.
Inspect ancillary bay probe lid cover gasket then position onto the ancillary bay cover.

Note
Confirm no visual damage present,Wipe ancillary bay with IPA to clean surface,Allow to 1 minute dry time.
Install bolts securing ancillary bay probe lid cover to ancillary bay cover.

Note
2x bolts, E10 5-Lobe, 6 Nm, Install new fasteners.
Remove HV insulating gloves.
Remove LH rear wheel center cap.

Note
1x cap.
Loosen LH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Remove RH rear wheel center cap.

Note
1x cap.
Loosen RH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Raise vehicle partially and lower lift onto locks.

Note
Set vehicle to a comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side.
Remove LH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Remove RH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Open trunk from exterior switch.
Remove LH trough trim .

Note
3x clips, 1x bolt, T20, 1.2Nm.
Remove RH trough trim.

Note
3x clips, 1x bolt, T20, 1.2Nm.
Remove bolt securing LH corner of rear fascia to body.

Note
1x bolt, 10mm, 4 Nm.
Remove bolt securing RH corner of rear fascia to body.

Note
1x bolt, 10mm, 4 Nm.
Raise vehicle fully and lower lift onto locks.

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects.
Remove LH and RH clips securing rear aero shield to wheel house liner.

Note
2x clips.
Remove rear aero shield.

Note
11x bolts, 10mm, 5 Nm.
Remove LH rear suspension cover.

Note
1x bolt, 10mm, 6 Nm, 2x tabs.
Remove RH rear suspension cover.

Note
1x bolt, 10mm, 6 Nm, 2x tabs.
Remove lower clips securing LH rear wheel liner.

Note
3x push clips.
Remove lower clips securing RH rear wheel liner.

Note
3x push clips.
Remove bolts securing the rear diffuser to body.

Note
4x bolts, 10mm, 4 Nm, 2x fastener covers.
Lower vehicle partially and set lift onto locks.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
Remove screw securing rear fascia to LH quarter panel.

Note
1x screw, T25, 2 Nm.
Remove screw securing rear fascia to RH quarter panel.

Note
1x screw, T25, 2 Nm.
Remove rear fascia and place on padded surface.

Note
2x connector, Recommendassistance.
Remove LH rear brake caliper from knuckle and hang from body.

Note
2x bolts, E18, 83 Nm, Discard after removal, Hand tighten lug nut to secure rotor on early production vehicles.
Install spring compressor onto LH rear coil spring.

Note
Tooling may vary per service center, Reference photos for clarification.
Unbolt LH damper from body at top mount.

Note
2x bolts, 15mm, 41 Nm.
Remove RH rear brake caliper from knuckle and hang from body.

Note
2x bolt, E18, 83 Nm, Discard bolts after removal, Hand tighten lug nut to secure rotor on early production vehicles.
Install spring compressor onto RH rear coil spring.

Note
Tooling may vary per service center, Reference photos for clarification.
Unbolt RH damper from body at top mount.

Note
2x bolts, 15mm, 41 Nm.
Remove nut securing RDU ground strap to vehicle.

Note
1x nut, 10mm, 10 Nm, Located at LH rear wheel well area.
Raise vehicle fully and lower lift onto locks.

Note
Set vehicle to comfortable working height, Make sure there's an audible click of the locks on both sides before lowering, otherwise vehicle may tilt to the side, Verify doors are clear of surrounding objects.
Disconnect RH side subframe harness connector.

Note
1x connector, Release locking tab.
Remove RH side subframe harness clip from body.

Note
1x barrel clip.
Remove nut securing LH rear stabilizer bar end link to stabilizer bar.

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal.
Remove stabilizer bar from LH rear end link.

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link.
Remove nut securing RH rear stabilizer bar end link to stabilizer bar.

Note
1x nyloc nut, 15mm, 55 Nm, Break nut loose then counter-hold ball joint with 5mm hex, Discard after removal.
Remove stabilizer bar from RH rear end link.

Note
May need to move the stabilizer bar up/down to get the correct angle to remove end link.
Remove bolts securing rear stabilizer bar to subframe and remove assembly.

Note
4x patch bolts, 11mm, 30 Nm, Discard after removal.
Release clips securing coolant hoses to LH shear plate.

Note
2x fir tree clips.
Release LH side hose clip from rear battery skid plate enclosure.

Note
1x fir tree clip.
Release RH side hose clips from rear battery skid plate enclosure.

Note
2x fir tree clips.
Release clips securing coolant hoses to RH shear plate.

Note
2x fir tree clips.
Remove lower bolts securing HV battery rear skid plate enclosure .

Note
2x bolts, EP10, 13 Nm, Older vins may be equipped with additional fastener count.
Remove upper nut securing HV battery rear skid plate enclosure .

Note
1x nut, 10mm, 13 Nm, Fastener count may vary on older built vehicles.
Remove upper bolts securing HV battery rear skid plate enclosure .

Note
4x bolts, 13mm, 35 Nm.
Remove HV battery rear skid plate enclosure .
Position coolant drain container underneath LH rear of HV battery.
Disconnect RDU inverter inlet tube from LH rear of HV battery.

Note
1x spring clip, Plug hose connections as needed, Coolant loss greater than 1 L will require vacuum fill.
Position coolant drain container underneath RH rear of vehicle.
Release push clips securing RH rear wheel liner to rocker panel.

Note
2x clips, Remove indicated clips and move liner aside for access.
Disconnect RDU outlet hose from PT return tube and plug both hose ends.

Note
1x spring clip,2x plugs, Lower hose located at RH rear of HV battery, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
Position coolant drain container underneath LH RDU area.
Disconnect RDU inverter inlet tube from fluid coupling.

Note
1x spring clip, 2x plugs, Plug the hose end and the fluid coupling.
Release RDU inverter inlet tube from RDU HV cable harness.

Note
1x fir tree clip.
Remove RDU inverter inlet hose from subframe.

Note
Maneuver hose as needed to remove from between rear subframe and RDU HV cable harness, Remove plugs from both ends and allow coolant to fully drain if discarding.
Remove coolant drain container from underneath vehicle.
Remove bolt securing RDU HV cable bracket to RDU.

Note
1x bolt, 10mm, 6 Nm.
Remove nut securing RDU HV cable bracket to HV battery.

Note
1x nut, 10mm, 10 Nm.
Disconnect RDU HV cable from HV battery.

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged.
Release RDU HV harness connection.

Note
1x connector, Release locking tab and rotate the release lever up to disengage the connector, Do not force the release lever up, Ensure the alignment tabs on the RDU header are not damaged.
Remove RDU HV harness.

Note
Rotate and route cable between subframe, rear drive unit and battery.
Place subframe lifting tool into position underneath rear subframe.
Connect air supply to subframe lifting tool.
Raise subframe lifting tool to support rear subframe.

Note
3x straps, Attach metal hooks at the end of straps to rings on subframe lifting tool and pull straps until secure, Lower the vehicle if necessary, Recommend assistance.
Mark LH rear and RH rear subframe bolts.

Note
2x bolts, Mark original location of subframe, Re-align during install, Can also mark subframe casting and subframe bushing to body if needed.
Remove smaller fasteners securing LH shear plate.

Note
2x bolts, 13mm, 35 Nm.
Remove large bolt securing LH shear plate and subframe to body and remove shear plate.

Note
1x bolt, 21mm, 130 Nm, Discard after removal.
Remove smaller fasteners for RH shear plate.

Note
2x bolts, 13mm, 35 Nm.
Remove large bolt securing RH shear plate and subframe to body and remove shear plate.

Note
1x bolt, 21mm, 130 Nm, Discard after removal.
Remove LH rear bolt securing subframe to body.

Note
1x bolt, 21mm, 165 Nm, Discard after removal.
Remove RH rear bolt securing subframe to body.

Note
1x bolt, 21mm, 165 Nm, Discard after removal.
Lower subframe and rear drive unit assembly from vehicle.

Note
Use caution while lowering subframe to avoid damage to surrounding components.
Disconnect air supply from subframe lifting tool.
Move the subframe lifting tool and subframe away from vehicle.

Note
Raise vehicle if necessary.
Release RDU ground strap clip from subframe.

Note
1x clip.
Remove ground strap harness from RDU assembly.

Note
1x bolt, 10mm, 6 Nm.
Position fluid catcher under subframe and fixture assembly.

Note
Position to catch all coolant loss, Use a foldable funnel as required for the next steps.
Release RDU inverter to oil cooler hose.

Note
1x hose clip, Image zoomed in for clarity.
Release RDU inverter coolant hose from heat exchanger.

Note
1x hose clip, Use a foldable funnel as required,.
Release clips securing RDU inverter to oil cooler hose and remove hose.

Note
4x clips.
Release coolant outlet hose from RDU heat exchanger and plug both ends.

Note
1x spring clip,2x plugs, Use shop towel to clean any residue coolant if necessary, Coolant loss greater than 1 L will require vacuum fill.
Release clips securing coolant outlet hose to rdu and remove hose.

Note
4x clips.
Release RDU logic connection clip.

Note
1x clip.
Release RDU logic connection.

Note
1x connector, Release locking tab then push the handle downward to release connector.
disconnect resolver connector.

Note
1x connector.
Release clips from rear drive unit.

Note
2x clips, .
Disconnect oil pump connector.

Note
1x connector.
Remove bolt securing LH rear wheel speed sensor to knuckle.

Note
1x bolt, 10mm, 5 Nm.
Remove grommet securing LH rear wheel speed sensor to knuckle.

Note
1x grommet.
Remove nut and bolt securing LH rear upper aft link to knuckle.

Note
1x bolt, 1x nut, 21mm, 134 Nm.
Remove nut and bolt securing LH rear upper fore link to knuckle.

Note
1x nut, 18mm, 76 Nm.
Remove nut and bolt securing LH rear toe link to knuckle.

Note
1x bolt, 1x nut, 18mm, 76 Nm.
Loosen nut and bolt securing LH rear lower fore link to knuckle, but do not remove fastener.

Note
1x bolt, 1x nut, 18mm, 76 Nm, Loosen fastener to allow further pivoting, Fastener does not need to be removed.
Separate LH half shaft from RDU using the cable removal kit.

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing, Remove cable when done.
Remove bolt securing RH wheel speed sensor to knuckle.

Note
1x bolt, 10mm, 5 Nm.
Remove grommet securing RH wheel speed sensor to knuckle.

Note
1x grommet.
Remove nut and bolt securing RH rear upper aft link to knuckle.

Note
1x bolt, 1x nut, 21mm, 134 Nm.
Remove nut and bolt securing RH rear upper fore link to knuckle.

Note
1x bolt, 1x nut, 18mm, 76 Nm.
Remove nut and bolt securing RH rear toe link to knuckle.

Note
1x bolt, 1x nut, 18mm, 76 Nm.
Loosen nut and bolt securing RH rear lower fore link to knuckle, but do not remove fastener.

Note
1x bolt, 1x nut, 18mm, 76 Nm, Loosen fastener to allow further pivoting, Fastener does not need to be removed.
Separate RH half shaft from RDU using the cable removal kit.

Note
1x U-bolt, 2x nuts, 10mm, Torque hand-tight, Wrap cable around inner joint, then tighten with U-bolt, Use slide hammer with cable eyelets to release, To avoid damage to the halfshaft boots and oil seals, exercise caution when removing, Remove cable when done.
Position the rear subframe assembly under gantry.
Attach drive unit sling tool to drive unit.

Note
3x hooks.
Secure drive unit sling to gantry.
Raise sling so there is slight tension on the cables.
Remove LH bolt securing drive unit to subframe.

Note
1x bolt, 18mm, 80 Nm.
Remove RH bolt securing drive unit to subframe.

Note
1x bolt, 18mm, 80 Nm.
Remove bolt securing rear of drive unit to subframe.

Note
1x bolt, 18mm, 80 Nm.
Raise sling to lift drive unit out of subframe.

Note
Carefully lift drive unit out of subframe, As the RDU is lifted maneuver the half shafts out of the way.
Move subframe and lifting tool from underneath drive unit.
Position empty drive unit crate below M3 drive unit .

Note
Use pallet if no empty crate available.
Lower drive unit into drive unit crate.

Note
Use pallet if no empty crate available.
Remove drive unit sling from gantry.
Remove drive unit sling tool from the removed drive unit.

Note
3x hooks.

Install

Attach drive unit sling tool to the replacement drive unit.

Note
3x hooks.
Secure drive unit sling to gantry.
Raise drive unit out of M3 drive unit crate.
Move subframe and lifting tool underneath drive unit.
Lower RDU into the rear subframe.

Note
Carefully lower rear drive unit into subframe, As the RDU is lowered maneuver the axles into drive unit for later installation.
Install rear bolt securing drive unit to subframe, hand tight.

Note
1x bolt, 18mm, 80 Nm, Torque at a later step.
Install RH bolt securing drive unit to subframe, hand tight.

Note
1x bolt, 18mm, 80 Nm, Torque at a later step.
Install LH bolt securing drive unit to subframe, hand tight.

Note
1x bolt, 18mm, 80 Nm, Torque at a later step.
Lower sling to release tension on the cables.
Torque motor mount bolts.

Note
3x bolts, 18mm, 80 Nm.
Release drive unit sling tool from RDU.

Note
3x shackles.
Move subframe assembly away from under gantry.
Position and align the RH half shaft axle splines into the RDU .

Note
Recommend assistance, Correctly position the axle splines into the drive unit, Take time to make sure they are seated together correctly, Do not force them together in a way they are not meant to mate, See images for reference, Lift up on RH knuckle as needed,.
Fully seat the RH rear half shaft into the RDU.

Note
1x half shaft, Straighten out the knuckle and half shaft assembly, Apply shifting force to seat the axle into the RDU, Take the time to verify the half shaft is fully seated, Do not apply an excessive amount force, If axle is not seating then make sure the splines are properly aligned and the assembly is leveled straight when seating.
Install RH rear toe link to knuckle and hand tighten nut and bolt.

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step.
Install RH rear upper fore link to knuckle and hand tighten nut and bolt.

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step.
Install RH upper aft link to knuckle and hand tighten nut and bolt.

Note
1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance.
Install grommet securing RH wheel speed sensor to knuckle.

Note
1x grommet.
Install bolt securing RH wheel speed sensor to knuckle.

Note
1x bolt, 10mm, 5 Nm.
Position and align the LH half shaft axle splines into the RDU .

Note
Recommend assistance, Correctly position the axle splines into the drive unit, Take time to make sure they are seated together correctly, Do not force them together in a way they are not meant to mate, See images for reference, Lift up on LH knuckle as needed,.
Fully seat the LH front half shaft into the RDU.

Note
1x half shaft, Straighten out the knuckle and half shaft assembly, Apply shifting force to seat the axle into the RDU, Take the time to verify the half shaft is fully seated, Do not apply an excessive amount force, If axle is not seating then make sure the splines are properly aligned and the assembly is leveled straight when seating.
Install LH rear toe link to knuckle and hand tighten nut and bolt.

Note
1x bolt, 1x nut, 18mm, 76 Nm, Recommend assistance, Torque at later step.
Install nut and bolt securing LH rear upper fore link to knuckle.

Note
1x bolt, 1x nut, 18mm, 76 Nm, Torque at later step.
Install LH upper aft link to knuckle and hand tighten nut and bolt.

Note
1x bolt, 1x nut, 21mm, 134 Nm, Recommend assistance.
Install grommet securing LH rear wheel speed sensor to knuckle.

Note
1x grommet.
Install LH wheel speed sensor to LH rear knuckle.

Note
1x bolt, 10mm, 5 Nm.
Connect oil pump connector.

Note
1x connector.
Secure clips onto rear drive unit.

Note
2x clips.
Connect resolver connector.

Note
1x connector.
Connect RDU logic connector.

Note
1x connector, Engage locking handle.
Secure RDU logic connection clip.

Note
1x clip.
Position and secure RDU outlet hose onto RDU assembly.

Note
4x fir tree clips.
Install RDU outlet hose to RDU heat exchanger.

Note
1x spring clips, 2x Plug, Remove plug from heat exchanger, Perform push-pull-push test to make sure hose is fully engaged, Clean excess coolant from area.
Position and secure RDU inverter to coolant hose onto RDU.

Note
4x clips.
Secure RDU inverter to oil cooler hose onto heat exchanger.

Note
1x spring clip, 1x plug, Clean excess coolant from area, Perform push-pull-push test to make sure hose is fully engaged.
Secure inverter to cooler hose to inverter.

Note
1x spring clip, Perform push-pull-push test to make sure hose is fully engaged.
Install ground strap harness onto RDU assembly.

Note
1x bolt, 10mm, 6 Nm.
Secure RDU ground strap clip onto subframe.

Note
1x clip.
Position subframe and and rear drive unit assembly under vehicle.
Connect air supply to subframe lifting tool.
Raise subframe and rear drive unit assembly into position.

Note
Use caution to not damage components while raising subframe.
Install RH rear bolt securing rear subframe to body hand tight.

Note
1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step.
Install LH rear bolt securing rear subframe to body hand tight.

Note
1x bolt, 21mm, 165 Nm, Install new bolt, Torque at later step.
Install LH front bolt and shear plate to rear subframe hand tight.

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
Install bolts securing LH shear plate to HV battery hand tight.

Note
2x bolts, 13mm, 35 Nm.
Install RH front bolt and shear plate to rear subframe hand tight.

Note
1x bolt, 21mm, 130 Nm, Install new bolt, Torque at later step.
Install bolts securing RH shear plate to HV battery hand tight.

Note
2x bolts, 13mm, 35 Nm.
Position subframe to marked location .

Note
Use previous markings to align subframe to body, Return to original position as close as possible.
Torque bolt securing RH rear of subframe to body.

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque.
Torque bolt securing LH rear of subframe to body.

Note
1x rear bolt, 21mm, 165 Nm, Mark bolt after torque.
Torque bolt securing subframe and LH shear plate to body.

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
Torque bolt securing subframe and RH shear plate to body.

Note
1x front bolt, 21mm, 130 Nm, Mark bolt after torque.
Torque bolts securing shear plates to vehicle.

Note
4x bolts, 13mm, 35 Nm.
Lower rear subframe lifting tool from vehicle.

Note
Verify yellow safety straps are removed from subframe.
Disconnect air supply from subframe lifting tool.
Remove subframe lifting tool from underneath vehicle.
Install RDU HV harness.

Note
Route cable between rear drive unit, subframe and battery, Rotate into connection position.
Connect RDU HV harness to RDU.

Note
1x connector, Install HV connector lever lock to RDU HV cable connector, Align connector to RDU then remove HV connector lever lock before fully latch connector, Use one hand to support the connector while other latching locking tab, Once installed, verify that the latch is not damaged and fully secured in the latched position.
Install bolt securing RDU HV cable bracket to RDU.

Note
1x location tab, 1x bolt, 10mm, 6 Nm.
Connect RDU HV cable to HV battery.

Note
1x connector, Make sure the connector lock is 90 degrees from the connector before beginning to secure the connector, Use one hand to support the connector while other latching locking tab. Once installed, verify that the latch is not damaged and fully secured in the latched position.
Install nut securing RDU HV cable bracket to HV battery.

Note
1x nut, 10mm, 10 Nm, Number of fasteners may vary.
Position coolant drain container underneath LH RDU area.
Install RDU inverter inlet tube into subframe.

Note
Maneuver hose as needed to position between rear subframe and RDU HV cable harness.
Remove plug from fluid coupling and connect RDU inverter inlet tube.

Note
1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged.
Secure RDU inverter inlet tube onto RDU HV cable harness.

Note
1x fir tree clip.
Position coolant drain container underneath LH rear of HV battery.
Remove plug from HV battery and connect RDU inverter inlet tube .

Note
1x spring clip, 1x plug, Perform push-pull-push test to make sure hose is fully engaged.
Position coolant drain container underneath RH rear of vehicle.
Install RDU outlet hose to PT return tube.

Note
1x spring clips, 2x Plug, Remove plug from PT retorn tube, Perform push-pull-push test to make sure hose is fully engaged, Clean excess coolant from area.
Secure push clips securing RH rear wheel liner to rocker panel.

Note
2x clips.
Remove coolant drain container from underneath vehicle.
Position HV battery rear skid plate enclosure onto HV battery for installation.

Note
Recommend assistance if needed.
Install upper bolts securing HV battery rear skid plate enclosure hand tight.

Note
4x bolts, 13mm, 35 Nm, Torque at later step.
Install upper nut securing HV battery rear skid plate enclosure hand tight.

Note
1x nut, 10mm, 13 Nm, Torque at later step.
Install lower bolts securing HV battery rear skid plate enclosure .

Note
2x bolts, EP10, 13 Nm, Earlier vins may be equipped with additional bolts.
Torque bolts securing HV battery rear skid plate enclosure to vehicle.

Note
4x bolts, 13mm, 35 Nm.
Torque upper nut securing HV battery rear skid plate enclosure .

Note
1x nut, 10mm, 13 Nm.
Install clips securing coolant hoses to RH shear plate.

Note
2x fir tree clips.
Install RH side hose clips to HV battery rear skid plate enclosure .

Note
2x fir tree clips.
Install LH side hose clip to HV battery rear skid plate enclosure .

Note
1x clip.
Install clips securing coolant hoses to LH shear plate.

Note
2x fir tree clips.
Position rear stabilizer bar into vehicle and install fasteners.

Note
4x patch bolts, 11mm, 30 Nm, Position rear stabilizer bar into vehicle, Thread in fasteners and torque down evenly, Install new patch bolts.
Position LH rear end link into stabilizer bar.

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link.
Install nut securing LH rear end link to stabilizer bar.

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque.
Position RH rear end link into stabilizer bar.

Note
Adjust the end link to align with stabilizer bar, Also may need to move the stabilizer bar up/down to get the correct angle to install end link.
Install nut securing RH rear end link to stabilizer bar.

Note
1x nyloc nut, 15mm, 55 Nm, Counter-hold ball joint with 5mm hex, Install new nyloc nut, Mark bolt after torque.
Install RH side subframe harness clip to body.

Note
1x barrel clip.
Connect RH side subframe harness connector.

Note
1x connector.
Lower vehicle partially and set lift onto locks.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
Install RDU ground strap.

Note
1x bolt, 10mm, 10 Nm, Re-install 1x washer if vehicle had this washer during removal, Located at LH rear wheel well area.
Install bolts securing LH damper to body at top mount.

Note
2x bolts, 15mm, 41 Nm.
Install LH rear brake caliper onto knuckle.

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle.
Remove bolt securing LH rear rotor to hub.

Note
1x bolt, 10mm, 5 Nm, Early production vehicles may not be equipped with bolt securing rotor.
Install hub jack adapter onto LH rear hub.

Note
5x lug nuts, 21mm, Hand tight.
Position and raise support stand to simulate LH rear suspension at ride height.
Use rear ride height torque gauge to verify RH suspension is set to ride height specification.

Note
May need to slightly adjust stand or spring compressor.
Measure from bottom of quarter panel to center of axle as a secondary check to make sure LH suspension is set to ride height.

Note
Distance should be 378 mm.
Torque bolt securing LH rear upper aft link to knuckle.

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen.
Torque bolt securing LH rear upper fore link to knuckle.

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen.
Torque bolt securing LH rear toe link to knuckle.

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen.
Torque bolt securing LH rear lower fore link to knuckle.

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen.
Remove support stand from underneath LH rear suspension.
Remove hub jack adapter from LH rear hub.

Note
5x lug nuts, 21mm, Hand tight.
Install bolt securing LH rear rotor to LH rear hub.

Note
1x bolt, 10mm, 5 Nm.
Remove spring compressor from LH rear coil spring.
Install bolts securing RH damper to body at top mount.

Note
2x bolts, 15mm, 41 Nm.
Install RH rear brake caliper onto knuckle.

Note
2x bolt, E18, 83 Nm, Install new bolts, Remove the S-hook from vehicle.
Remove bolt securing RH rotor to hub.

Note
1x bolt, 10mm, 5 Nm.
Install hub jack adapter onto RH rear hub.

Note
5x lug nuts, 21mm, Hand tight.
Position and raise support stand to simulate RH rear suspension at ride height.
Use rear ride height torque gauge to verify RH suspension is set to ride height specification.

Note
May need to slightly adjust stand or spring compressor.
Measure from bottom of quarter panel to center of axle as a secondary check to make sure RH suspension is set to ride height.

Note
Distance should be 378 mm.
Torque bolt securing RH rear upper aft link to knuckle.

Note
1x bolt, 21mm, 134 Nm, Mark with paint pen.
Torque bolt securing RH rear upper fore link to knuckle.

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen.
Torque bolt securing RH rear toe link to knuckle.

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen.
Torque bolt securing RH rear lower fore link to knuckle.

Note
1x bolt, 18mm, 76 Nm, Mark with paint pen.
Remove support stand from underneath RH suspension.
Remove hub jack adapter from RH rear hub.

Note
5x lug nuts, 21mm, Hand tight.
Install bolt securing RH rotor to hub.

Note
1x bolt, 10mm, 5 Nm.
Remove spring compressor from RH rear coil spring.

Note
Tooling may vary per service center.
Install rear fascia.

Note
2x connector, Recommendassistance.
Raise vehicle fully and lower lift onto locks.

Note
Set vehicle to comfortable working height, Make sure there's an audible click of locks on both sides before lowering, otherwise vehicle may tilt to side.
Install LH rear suspension cover.

Note
1x bolt, 10mm, 6 Nm, 2x tabs.
Install RH rear suspension cover.

Note
1x bolt, 10mm, 6 Nm, 2x tabs.
lnstall rear aero shield.

Note
11x bolts, 10mm, 5 Nm, Apply Loctite 222 onto rear aero shield bolts.
Install LH and RH clips securing rear aero shield to wheel house liner.

Note
2x clips.
Apply Loctite 222 onto bolts and install bolts securing rear diffuser to body.

Note
4x bolts, 10mm, 4 Nm, 2x fastener covers.
Lower vehicle partially and set onto locks.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered, Set vehicle to comfortable working height.
Install screw securing rear fascia to LH quarter panel.

Note
1x screw, T25, 2 Nm.
Install screw securing rear fascia to RH quarter panel.

Note
1x screw, T25, 2 Nm.
Install lower clips securing RH rear wheel liner.

Note
3x push clips.
Install lower clips securing LH rear wheel liner.

Note
3x push clips.
Install bolt securing RH corner of rear fascia.

Note
1x bolt, 10mm, 4 Nm.
Install bolt securing LH corner of rear fascia.

Note
1x bolt, 10mm, 4 Nm.
Install RH trough trim.

Note
3x clips, 1x bolt, T20, 1.2Nm.
Install LH trough trim.

Note
3x clips, 1x bolt, T20, 1.2Nm.
Close trunk via interior switch.
Install LH rear wheel.

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool.
Install RH rear wheel.

Note
5x nuts, 21mm, 175 Nm, Start lug nuts by hand before using power tool.
Lower vehicle fully.

Note
Raise lift off locks, then hold lock release lever to keep locks free while vehicle is lowered.
Torque LH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Torque RH rear wheel.

Note
5x nuts, 21mm, 175 Nm.
Install LH rear wheel center cap.

Note
1x cap, Verify emblem is aligned with valve stem.
Install RH rear wheel center cap.

Note
1x cap, Verify emblem is aligned with valve stem.
Remove coolant bottle cap.
Place empty coolant container into front storage area.
Fill container with at least 15L of coolant.
Place filled coolant container into front storage area.
Install refill tool cap onto coolant bottle assembly.
Setup vacuum refill tool.

Note
Verify all valves on refill tool are in the closed position, See image for clarity.
Install vacuum refill hose into refill cap on coolant bottle.

Note
Perform push-pull-push test to verify hose is fully engaged.
Position overflow hose into empty container.
Place refill hose inside filled coolant container .

Note
Make sure hose end is fully submerged into coolant.
Connect shop air supply to coolant refill tool.

Note
If not already done, Verify refill valve is set to off.
Open air inlet valve to draw a vacuum, Once gauge stabilizes, Fully close valve.

Note
Gauge stabilizes roughly (60-70 cmHg), Vacuum should not drop after the valves are closed.
Slowly open coolant refill valve to allow coolant to be drawn into coolant refill hose, Close valve when hose is full of coolant.

Note
This purges trapped air from the hose.
Monitor gauge for 30 seconds to verify a vacuum is maintained in cooling system.
Reopen the air inlet valve for 3 minutes to continue evacuating cooling system, then close valve.
Slowly open refill valve to allow coolant to be drawn into system.

Note
Make sure hose end of refill hose is fully submerged during entire process.
Once gauge reads zero, close refill valve.
Disconnect shop air supply from coolant refill tool.
Remove coolant refill hose from coolant container.
Remove coolant overflow hose from coolant container.
Remove vacuum refill hose from refill cap on coolant bottle.
Remove coolant refill tool from vehicle.
Remove both coolant containers from inside underhood area.
Connect 2nd row seat harness and secure cushion.

Note
2x clips, 2x connectors, Insert buckles through holes, Slide rear inward then align front clips, Perform push-pull-push test.
Connect first responder loop and leave LV battery disconnected.

Note
1x connector, Engage locking tab, Connect FRL but leave LV battery disconnected.
Connecting low-voltage battery maintenance equipment.

Note
Release positive terminal cover, Secure positive terminal to jump post, Secure negative terminal to bolt located between brake fluid reservoir and front trunk, Connect maintainer to power supply, To avoid damaging the vehicle DO NOT allow positive cable to make contact with other metal components, Never have a float charger and the LV battery simultaneously connected for any extended period of time.
Hold brake pedal and select park on UI to disable EPB service mode.
On the touchscreen, select Service Mode > Thermal.
Select "Stop Thermal Fill Drain" through UI.

Note
Allow routine to complete, ensure routine is successful.
Connect to vehicle using Toolbox 3.0.

Note
Vehicle connection is integrated into drivers footwell cover, Open Toolbox 3 website and establish connection to the vehicle.
In toolbox, click the Actions/Autodiag tab, type "Redeploy" in the search field, click on SERVICE CAN REDEPLOY and then click Run.

Note
Allow the routine to complete.

Note
Once the firmware redeploy is complete, verify on the touchscreen release notes are present.
Disconnect low-voltage battery maintenance equipment and connect LV battery.

Note
LV Battery Maintainer 1849737-N0-A7.
On touchscreen, select Thermal > Coolant System > Coolant Purge to start the Coolant Air Purge routine and allow the routine to complete.
Tip:
- The routine will last for a while after the stop message displays. The coolant pumps are audible.
- The test lasts for approximately 10 mins. Do not start another routine during this time.
- Make sure that the vehicle is not in Drive. Putting the vehicle into Drive will stop this routine.
- The speed in the test varies from 3500-6500 RPM (idle speed = ~1500 RPM) and the actuated valve varies between SERIES and PARALLEL.
- The speed can be monitored in Garage under the PT Thermal tab. If the speed hovers at 7000 RPM, it indicates the pumps are air locked. Perform the vacuum fill again. Continue to add the coolant and purge until the coolant level reaches between the NOM and MAX Lines on the bottle.
Remove diagnostic cable from port to disconnect Toolbox 3.0 from vehicle.
Inspect coolant level and top off as necessary.

Note
Ensure that fluid level is at Max line.
Install coolant bottle cap.
Perform Thermal Performance through the UI.

Note
Select Thermal > Actions > Test Thermal Performance, click Run, close once routine is completed.
Install the rear underhood apron. See Underhood Apron - Rear (Remove and Replace).
Move LH and RH front seats to original position.
Disable Service Mode. See Service Mode.
Raise all windows and close all doors.
Remove the lift arms from below vehicle.
For China, Japan and Korea only: Carefully remove the old motor label from the hood, and install a new motor label to match the new motor information.
In this procedure, the front or rear subframe was removed and reinstalled. Therefore, refer to the Alignment Requirement tables to determine whether an EPAS alignment check (EC) or four wheel alignment check (AC) is necessary. If performed, add the alignment check/adjust as a separate activity. See Alignment Requirement - Suspension.

Rear Drive Unit - Mosfet - HC (3DU) (Remove and Replace)

Remove

Install

Figure 1

Figure 2

Figure 3